ME(w/o STI)-172

Cam Carrier

MECHANICAL

20.Cam Carrier

A: REMOVAL

1. CAM CARRIER RH

1) Remove the engine from the vehicle. <Ref. to ME(w/o STI)-48, REMOVAL, Engine Assembly.>

2) Remove the chain cover. <Ref. to ME(w/o STI)-93, REMOVAL, Chain Cover.>

3) Remove the timing chain RH. <Ref. to ME(w/o STI)-116, TIMING CHAIN RH, REMOVAL, Timing Chain

Assembly.>

4) Remove the rocker cover RH. <Ref. to ME(w/o STI)-152, ROCKER COVER RH, REMOVAL, Rocker Cov-

er.>

5) Remove the clip holding the engine harness from cam carrier RH.

ME-06694

15WRX_STI_US_EN.book 172 ページ２０１５年２月１３日　金曜日　午前１１時２０分

ME(w/o STI)-173

Cam Carrier

MECHANICAL

6) Remove the oil pipe assembly from the scavenge pump and cam carrier RH.

7) Disconnect the water pipe hose from oil pan upper and EGR cooler, and remove the water pipe assembly.

ME-07995

ME-06696

15WRX_STI_US_EN.book 173 ページ２０１５年２月１３日　金曜日　午前１１時２０分

ME(w/o STI)-174

Cam Carrier

MECHANICAL

8) When disassembling the cam carrier RH

NOTE:

When disassembling the cam carrier RH, perform the following steps also.

(1) Remove the scavenge pump. <Ref. to LU(w/o STI)-43, REMOVAL, Scavenge Pump.>

(2) Remove the cam sprocket RH. <Ref. to ME(w/o STI)-141, CAM SPROCKET RH, REMOVAL, Cam

Sprocket.>

9) Set the part so that the cam carrier RH is on the upper side.

10) Loosen the bolts holding the cam carrier RH equally, a little at a time in numerical sequence as shown

in the figure and remove the cam carrier RH.

11) Remove the O-ring and the roller rocker arm from cylinder head RH.

NOTE:

Be careful not to confuse the roller rocker arms.

ME-07996

(2)

(1)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

ME-06698

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ME(w/o STI)-175

Cam Carrier

MECHANICAL

12) Remove the valve shim and the roller rocker arm pivot from cylinder head RH.

NOTE:

Be careful not to confuse the valve shim and the roller rocker arm pivot.

13) Remove the liquid gasket from cam carrier RH and cylinder head RH.

2. CAM CARRIER LH

1) Remove the engine from the vehicle. <Ref. to ME(w/o STI)-48, REMOVAL, Engine Assembly.>

2) Remove the chain cover. <Ref. to ME(w/o STI)-93, REMOVAL, Chain Cover.>

3) Remove the timing chain LH. <Ref. to ME(w/o STI)-119, TIMING CHAIN LH, REMOVAL, Timing Chain

Assembly.>

4) Remove the intake manifold. <Ref. to FU(w/o STI)-18, REMOVAL, Intake Manifold.>

5) Remove the rocker cover LH. <Ref. to ME(w/o STI)-154, ROCKER COVER LH, REMOVAL, Rocker Cov-

er.>

6) Remove the clip holding the engine harness from cam carrier LH.

ME-06699

ME-07391

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ME(w/o STI)-176

Cam Carrier

MECHANICAL

7) Remove the fuel pipe protector from the high-pressure fuel pump case.

8) Remove the fuel pump insulator (A) from the high-pressure fuel pump, and then remove the fuel pipe in-

sulator No. 1 (B) from the high-pressure fuel delivery pipe.

ME-06701

ME-07997

(B)

(A)

15WRX_STI_US_EN.book 176 ページ２０１５年２月１３日　金曜日　午前１１時２０分

ME(w/o STI)-177

Cam Carrier

MECHANICAL

9) Disconnect the connector (A) from the high-pressure fuel pump, and remove the fuel delivery pipe from the

high-pressure fuel pump.

NOTE:

Disconnect the quick connector as shown in the figure.

(a) Slider

ME-05201

(a)

ME-07998

(A)

15WRX_STI_US_EN.book 177 ページ２０１５年２月１３日　金曜日　午前１１時２０分

ME(w/o STI)-178

Cam Carrier

MECHANICAL

10) Remove the high-pressure fuel delivery pipe from the high-pressure fuel pump and fuel injector pipe.

11) Disconnect the water pipe hose from oil pan upper, and remove the water pipe assembly.

12) When disassembling the cam carrier LH

NOTE:

When disassembling the cam carrier LH, perform the following steps also.

(1) Remove the high-pressure fuel pump. <Ref. to FU(w/o STI)-74, REMOVAL, High Pressure Fuel

Pump.>

(2) Remove the cam sprocket LH. <Ref. to ME(w/o STI)-142, CAM SPROCKET LH, REMOVAL, Cam

Sprocket.>

ME-07999

ME-07392

15WRX_STI_US_EN.book 178 ページ２０１５年２月１３日　金曜日　午前１１時２０分

ME(w/o STI)-179

Cam Carrier

MECHANICAL

13) Set the part so that the cam carrier LH is on the upper side.

14) Loosen the bolts holding the cam carrier LH equally, a little at a time in numerical sequence as shown in

the figure and remove the cam carrier LH.

15) Remove the O-ring and the roller rocker arm from cylinder head LH.

NOTE:

Be careful not to confuse the roller rocker arms.

ME-08000

(2)

(1)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

ME-06706

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ME(w/o STI)-180

Cam Carrier

MECHANICAL

16) Remove the valve shim and the roller rocker arm pivot from cylinder head LH.

NOTE:

Be careful not to confuse the valve shim and the roller rocker arm pivot.

17) Remove the liquid gasket from cam carrier LH and cylinder head LH.

B: INSTALLATION

1. CAM CARRIER RH

1) Set the part so that the cylinder head RH is on the upper side.

2) Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller

rocker arm pivot to the cylinder head RH.

ME-06707

ME-06699

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ME(w/o STI)-181

Cam Carrier

MECHANICAL

3) Apply engine oil to the O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to

the cylinder head RH.

NOTE:

Use new O-rings.

ME-06698

15WRX_STI_US_EN.book 181 ページ２０１５年２月１３日　金曜日　午前１１時２０分

ME(w/o STI)-182

Cam Carrier

MECHANICAL

4) Apply liquid gasket to the mating surface of cam carrier RH as shown in the figure.

NOTE:

• Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder head RH and cam

carrier RH.

• Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:

0.5 mm (0.1181

0.0197 in)

(A) Range A (D) Liquid gasket applying position of

mating surfaces other than range

(G) 0±0.5 mm (0±0.0197 in)

(B) φ18 mm (0.7087 in) (E) φ3±0.5 mm (0.1181±0.0197 in) (H) Chamfer edge

mating surfaces of range A

(F) 1 mm (0.0394 in) or less

ME-06708

A-A

(C)

B-B

(D)

(H)

(F)

(E)

(H)

(G)

(E)

(A)

(B)

(A)

(B)

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ME(w/o STI)-183

Cam Carrier

MECHANICAL

5) Install the cam carrier RH to the cylinder head RH.

(1) Mount the cam carrier RH, then tighten all bolts with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in nu-

merical order as shown in the figure.

NOTE:

Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position as shown in the figure.

ME-08001

ME-08002

(8)

(9)

(7)

(6)

(5)

(4)

(3)

(2)

(1)

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ME(w/o STI)-184

Cam Carrier

MECHANICAL

(2) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.

(3) Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown

in the figure.

ME-08003

(1)

(2)

(3)

ME-08004

(3)

(2)

(1)

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ME(w/o STI)-185

Cam Carrier

MECHANICAL

(4) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.

(5) Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown

in the figure.

ME-08005

(1)

(2)

(3)

ME-08006

(3)

(2)

(1)

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ME(w/o STI)-186

Cam Carrier

MECHANICAL

(6) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.

(7) Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown

in the figure.

NOTE:

After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely re-

move any squeezed-out liquid gasket.

6) Set the part so that the intake manifold is on the upper side.

ME-08007

(2)

(1)

(3)

ME-08008

(2)

(3)

(1)

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ME(w/o STI)-187

Cam Carrier

MECHANICAL

7) When the cam carrier RH has been disassembled

NOTE:

When the cam carrier RH has been disassembled, perform the following steps also.

(1) Install the cam sprocket RH. <Ref. to ME(w/o STI)-144, CAM SPROCKET RH, INSTALLATION, Cam

Sprocket.>

(2) Install the scavenge pump. <Ref. to LU(w/o STI)-44, INSTALLATION, Scavenge Pump.>

NOTE:

When installing the scavenge pump, do not turn the intake camshaft RH to the outside of range of zero-lift (in

range where it can be turned lightly by hand).

8) Check the cam clearance. <Ref. to ME(w/o STI)-43, WHEN TIMING CHAIN ASSEMBLY IS REMOVED,

INSPECTION, Cam Clearance.>

9) Connect the water pipe hose to oil pan upper and EGR cooler, and install the water pipe assembly.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ME-06696

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ME(w/o STI)-188

Cam Carrier

MECHANICAL

10) Install the oil pipe assembly to the scavenge pump and cam carrier RH.

(1) Set the oil pipe assembly to the scavenge pump and cam carrier RH, and temporarily tighten the bolts

which secure the oil pipe assembly to the scavenge pump and cam carrier RH.

NOTE:

Use a new gasket.

ME-07995

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ME(w/o STI)-189

Cam Carrier

MECHANICAL

(2) Tighten the bolts which secure the oil pipe assembly to the scavenge pump and cam carrier RH in nu-

merical order as shown in the figure.

Tightening torque:

T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T2: 29 N·m (3.0 kgf-m, 21.4 ft-lb)

11) Secure the engine harness to the cam carrier RH with a clip.

12) Install the rocker cover RH. <Ref. to ME(w/o STI)-161, ROCKER COVER RH, INSTALLATION, Rocker

Cover.>

13) Install the timing chain RH. <Ref. to ME(w/o STI)-133, TIMING CHAIN RH, INSTALLATION, Timing

Chain Assembly.>

14) Install the chain cover. <Ref. to ME(w/o STI)-101, INSTALLATION, Chain Cover.>

ME-08009

(2)

(1)

(3)

(4)

ME-06694

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ME(w/o STI)-190

Cam Carrier

MECHANICAL

15) Install the engine to the vehicle. <Ref. to ME(w/o STI)-61, INSTALLATION, Engine Assembly.>

2. CAM CARRIER LH

1) Set the part so that the cylinder head LH is on the upper side.

2) Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller

rocker arm pivot to the cylinder head LH.

3) Apply engine oil to the O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to

the cylinder head LH.

NOTE:

Use new O-rings.

ME-06707

ME-06706

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ME(w/o STI)-191

Cam Carrier

MECHANICAL

4) Apply liquid gasket to the mating surface of cam carrier LH as shown in the figure.

NOTE:

• Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder head LH and cam

carrier LH.

• Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:

0.5 mm (0.1181

0.0197 in)

(A) Range A (D) Liquid gasket applying position of

mating surfaces other than range

(G) 0±0.5 mm (0±0.0197 in)

(B) φ18 mm (0.7087 in) (E) φ3±0.5 mm (0.1181±0.0197 in) (H) Chamfer edge

mating surfaces of range A

(F) 1 mm (0.0394 in) or less

ME-06749

A-A

(C)

B-B

(D)

(H)

(F)

(E)

(H)

(G)

(E)

(A)

(B)

(A)

(B)

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ME(w/o STI)-192

Cam Carrier

MECHANICAL

5) Install the cam carrier LH to the cylinder head LH.

(1) Mount the cam carrier LH, then tighten all bolts with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in nu-

merical order as shown in the figure.

NOTE:

Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position as shown in the figure.

ME-06718

ME-08011

(8)

(9)

(7)

(6)

(5)

(4)

(3)

(2)

(1)

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ME(w/o STI)-193

Cam Carrier

MECHANICAL

(2) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.

(3) Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown

in the figure.

ME-08012

(1)

(2)

(3)

ME-08013

(3)

(2)

(1)

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ME(w/o STI)-194

Cam Carrier

MECHANICAL

(4) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.

(5) Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown

in the figure.

ME-08014

(1)

(2)

(3)

ME-08015

(3)

(2)

(1)

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ME(w/o STI)-195

Cam Carrier

MECHANICAL

(6) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.

(7) Tighten the bolts (3 places) with a torque of 18 N·m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown

in the figure.

NOTE:

After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely re-

move any squeezed-out liquid gasket.

6) Set the part so that the installation surface of the intake manifold is on the upper side.

ME-08016

(3)

(1)

(2)

ME-08017

(1)

(3)

(2)

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ME(w/o STI)-196

Cam Carrier

MECHANICAL

7) When the cam carrier LH has been disassembled

NOTE:

When the cam carrier LH has been disassembled, perform the following steps also.

(1) Install the cam sprocket LH. <Ref. to ME(w/o STI)-147, CAM SPROCKET LH, INSTALLATION, Cam

Sprocket.>

(2) Install the high-pressure fuel pump. <Ref. to FU(w/o STI)-78, INSTALLATION, High Pressure Fuel

Pump.>

NOTE:

Install the high-pressure fuel pump so that the cam lobes on the intake camshaft LH are positioned as shown

in the figure. Perform adjustment within the range of zero-lift (in range where it can be turned lightly by hand).

8) Check the cam clearance. <Ref. to ME(w/o STI)-43, WHEN TIMING CHAIN ASSEMBLY IS REMOVED,

INSPECTION, Cam Clearance.>

ME-06726

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ME(w/o STI)-197

Cam Carrier

MECHANICAL

9) Connect the water pipe hose to oil pan upper, and install the water pipe assembly.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

10) Temporarily tighten the flare nuts of the high-pressure fuel delivery pipe to the high-pressure fuel pump

and fuel injector pipe by hand until they are seated, and then tighten the flare nuts.

CAUTION:

Always use a new high-pressure fuel delivery pipe.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

ME-07392

ME-07999

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ME(w/o STI)-198

Cam Carrier

MECHANICAL

11) Install the fuel delivery pipe to the high-pressure fuel pump, and connect the connector (A) to the high-

pressure fuel pump.

CAUTION:

• Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface

of the pipe.

• When connecting the quick connector, make sure to insert it all the way in before locking the slider.

• When it is difficult to lock the slider, check that the connector is fully inserted.

• After locking the slider, check again that the quick connector is securely connected.

NOTE:

Connect the quick connector as shown in the figure.

(a) Slider

ME-05211

(a)

ME-07998

(A)

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ME(w/o STI)-199

Cam Carrier

MECHANICAL

12) Install the fuel pump insulator (A) to the high-pressure fuel pump, and then install the fuel pipe insulator

No. 1 (B) to the high-pressure fuel delivery pipe.

NOTE:

By pushing the sections (a) shown in the figure, fix the fuel pipe insulator No. 1 (B) to the high-pressure fuel

delivery pipe.

13) Temporarily tighten the bolts securing the fuel pipe protector to the high-pressure fuel pump case.

ME-08018

(a)

(B)

(A)

ME-06701

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ME(w/o STI)-200

Cam Carrier

MECHANICAL

14) Secure the engine harness to the cam carrier LH with a clip.

15) Install the rocker cover LH. <Ref. to ME(w/o STI)-163, ROCKER COVER LH, INSTALLATION, Rocker

Cover.>

16) Install the intake manifold. <Ref. to FU(w/o STI)-29, INSTALLATION, Intake Manifold.>

17) Tighten the bolts securing the fuel pipe protector to the high-pressure fuel pump case.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

18) Install timing chain LH. <Ref. to ME(w/o STI)-124, TIMING CHAIN LH, INSTALLATION, Timing Chain

Assembly.>

19) Install the chain cover. <Ref. to ME(w/o STI)-101, INSTALLATION, Chain Cover.>

20) Install the engine to the vehicle. <Ref. to ME(w/o STI)-61, INSTALLATION, Engine Assembly.>

ME-07391

ME-08030

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ME(w/o STI)-201

Cam Carrier

MECHANICAL

C: DISASSEMBLY

1. CAM CARRIER RH

1) Remove the oil pipe from cam carrier RH.

2) Loosen the bolts (front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH,

exhaust center camshaft cap RH, and exhaust rear camshaft cap RH) equally, a little at a time in numerical

sequence as shown in the figure, and remove each camshaft cap.

NOTE:

Arrange camshaft caps in order so that they can be installed in their original positions.

ME-06728

ME-06729

(5)

(9)

(1)

(2)

(4)

(3)

(11)

(12)

(10)

(7)

(8)

(6)

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ME(w/o STI)-202

Cam Carrier

MECHANICAL

3) Remove the intake camshaft RH and the exhaust camshaft RH from cam carrier RH.

4) Remove the filter from cam carrier RH.

5) Remove the liquid gasket from cam carrier RH and front camshaft cap RH, intake rear camshaft cap RH

and exhaust rear camshaft cap RH.

ME-06730

ME-06731

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ME(w/o STI)-203

Cam Carrier

MECHANICAL

2. CAM CARRIER LH

1) Loosen the bolts (front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, ex-

haust center camshaft cap LH and exhaust rear camshaft cap LH) equally, a little at a time in numerical se-

quence as shown in the figure, and remove each camshaft cap.

NOTE:

Arrange camshaft caps in order so that they can be installed in their original positions.

2) Remove the intake camshaft LH and the exhaust camshaft LH from cam carrier LH.

ME-06732

(1)

(6)

(8)

(9)

(7)

(12)

(13)

(11)

(2)

(4)

(3)

(5)

(10)

ME-06733

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ME(w/o STI)-204

Cam Carrier

MECHANICAL

3) Remove the filter from cam carrier LH.

4) Remove the liquid gasket from cam carrier LH and front camshaft cap LH, intake rear camshaft cap LH

and exhaust rear camshaft cap LH.

D: ASSEMBLY

1. CAM CARRIER RH

1) Install the filter to the cam carrier RH.

NOTE:

Use a new filter.

Filter insert position:

Cam carrier RH end face 0

–0.5

mm (

–0.0197

in) position

(A) 0 — 0.5 mm (0 — 0.0197 in)

ME-06734

ME-06735

A-A

(A)

B-B

(A)

B B

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ME(w/o STI)-205

Cam Carrier

MECHANICAL

2) Set the intake camshaft RH and the exhaust camshaft RH to the cam carrier RH.

NOTE:

Apply engine oil to the journals of cam carrier RH before setting the intake camshaft RH and exhaust cam-

shaft RH.

3) Install the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust

center camshaft cap RH and exhaust rear camshaft cap RH.

(1) Apply liquid gasket to the mating surface of front camshaft cap RH, intake rear camshaft cap RH and

exhaust rear camshaft cap RH as shown in the figure.

CAUTION:

• Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow to-

ward camshaft journal, resulting in engine seizure.

• Do not apply liquid gasket excessively to the intake center camshaft cap RH and exhaust center

camshaft cap RH.

NOTE:

• Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap RH, in-

take rear camshaft cap RH, exhaust rear camshaft cap RH, and cam carrier RH.

• Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:

Mating surfaces other than ranges A and B

0.5 mm (0.0787

0.0197 in)

Mating surfaces of range A

–0.5

mm (0.1181

+0.0394

–0.0197

in)

Mating surfaces of range B

3.5

0.5 mm (0.1378

0.0197 in)

(A) 28.5 mm (1.122 in) (E) Liquid gasket applying position of

mating surfaces of range B

(I) Chamfer edge

(B) Range A (F) Liquid gasket applying position of

mating surfaces other than range

A and range B

(J) 1 mm (0.0394 in) or less

(D) Liquid gasket applying position of

mating surfaces of range A

(H) φ3

–0.5

(0.1181

+0.0394

–0.0197

in)

(L) φ2±0.5 mm (0.0787±0.0197 in)

ME-06736

A-A

(D)

:(B)

:(C)

C-C

(F)

B-B

(E)

(L)

(I)

(J)

(G)

(H)

(I)

(K)

(I)

(J)

(A)

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ME(w/o STI)-206

Cam Carrier

MECHANICAL

(2) Apply engine oil to the journals of each camshaft cap before setting the camshaft cap.

(3) Tighten the bolts which secure front camshaft cap RH, intake center camshaft cap RH, intake rear

camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH in numerical order

as shown in the figure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

4) Install the oil pipe to the cam carrier RH.

(1) Set the oil pipe to the cam carrier RH, and temporarily tighten the bolts which secure the oil pipe to the

cam carrier RH.

NOTE:

Use a new gasket.

ME-06737

(5)

(9)

(1)

(2)

(4)

(3)

(11)

(12)

(10)

(7)

(8)

(6)

ME-06728

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ME(w/o STI)-207

Cam Carrier

MECHANICAL

(2) Tighten the bolts which secures the oil pipe to the cam carrier RH in numerical order as shown in the

figure.

Tightening torque:

T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T2: 31 N·m (3.2 kgf-m, 22.9 ft-lb)

2. CAM CARRIER LH

1) Install the filter to the cam carrier LH.

NOTE:

Use a new filter.

Filter insert position:

Cam carrier LH end face 0

–0.5

mm (

–0.0197

in) position

2) Set the intake camshaft LH and the exhaust camshaft LH to the cam carrier LH.

NOTE:

Apply engine oil to the journals of cam carrier LH before setting the intake camshaft LH and exhaust camshaft LH.

(A) 0 — 0.5 mm (0 — 0.0197 in)

ME-08010

(3)

(2)

(1)

ME-06738

A-A

B-B

(A)

B B

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ME(w/o STI)-208

Cam Carrier

MECHANICAL

3) Install the front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust

center camshaft cap LH and exhaust rear camshaft cap LH.

(1) Apply liquid gasket to the mating surface of front camshaft cap LH, intake rear camshaft cap LH and

exhaust rear camshaft cap LH as shown in the figure.

CAUTION:

• Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow to-

ward camshaft journal, resulting in engine seizure.

• Do not apply liquid gasket excessively to the intake center camshaft cap LH and exhaust center

camshaft cap LH.

NOTE:

• Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap LH, in-

take rear camshaft cap LH, exhaust rear camshaft cap LH, and cam carrier LH.

• Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:

Mating surfaces other than ranges A, B and C

0.5 mm (0.0787

0.0197 in)

Mating surfaces of range A

3.5

0.5 mm (0.1378

0.0197 in)

Mating surfaces of range B

0.5 mm (0.1181

0.0197 in)

Mating surfaces of range C

–0.5

mm (0.1181

+0.0394

–0.0197

in)

(A) 28.5 mm (1.122 in) (G) Liquid gasket applying position of

mating surfaces of range A

(M) Chamfer edge

(B) 11.6 mm (0.4567 in) (H) Liquid gasket applying position of

mating surfaces of range B

(N) φ3±0.5 mm (0.1181±0.0197 in)

mating surfaces of range C

(O) φ3

–0.5

(0.1181±

+0.0394

–0.0197

in)

(D) Range A (J) Liquid gasket applying position of

mating surfaces other than range

A, range B and range C

(P) 1 mm (0.0394 in) or less

(E) Range B (K) 0.5 mm (0.0197 in) (Q) φ2±0.5 mm (0.0787±0.0197 in)

(F) Range C (L) φ3.5±0.5 mm (0.1378±0.0197 in)

ME-06740

(L)

A-A

(G)

:(D)

:(E)

:(F)

(A)

C-C

(I)

B-B

(H)

(K)

(M)

(K)

(N)

D-D

(J)

(Q)

(M)

(P)

(O)

(K)

(M)

(C)

(B)

(C)

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ME(w/o STI)-209

Cam Carrier

MECHANICAL

(2) Apply engine oil to the journals of each camshaft cap before setting the camshaft cap.

(3) Tighten the bolts which secure front camshaft cap LH, intake center camshaft cap LH, intake rear

camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH in numerical order

as shown in the figure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

E: INSPECTION

1) Visually check the cam carrier filter, and if clogging is found, replace with a new part.

2) Check the camshaft journals for damage and wear. Replace the camshaft if faulty.

3) Check the cam face condition of camshaft, and remove the minor faults by grinding with oil stone. Replace

the camshaft if uneven wear is found.

ME-06741

(4)

(8)

(6)

(5)

(7)

(11)

(10)

(12)

(3)

(1)

(2)

(9)

(13)

ME-08019

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ME(w/o STI)-210

Cam Carrier

MECHANICAL

4) Using a dial gauge, check the camshaft bend. If it exceeds the limit, replace the camshaft.

NOTE:

Measurement should be performed at a temperature of 20°C (68°F).

Camshaft bend:

Limit

0.020 mm (0.00079 in)

ME-05235

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ME(w/o STI)-211

Cam Carrier

MECHANICAL

5) Check the cam lobe height “H” and cam base circle diameter “A” of camshaft as shown in the figure, using

micrometer. If it is not within the standard, replace the camshaft.

NOTE:

• Measurement should be performed at a temperature of 20°C (68°F).

• Perform measurement of cam lobe height for fuel pump drive section at three points.

Camshaft cam lobe overall height H:

Intake

Valve drive section

Standard

40.34 — 40.44 mm (1.588 — 1.592 in)

Fuel pump drive section

Standard

41.95 — 42.05 mm (1.652 — 1.656 in)

Exhaust

Standard

40.20 — 40.30 mm (1.583 — 1.587 in)

Camshaft cam base circle diameter A:

Standard

34.0 mm (1.339 in)

(A) Valve drive section (B) Fuel pump drive section

ME-06743

(A)

(B)

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ME(w/o STI)-212

Cam Carrier

MECHANICAL

6) Check the camshaft journal outer diameter using micrometer. If it is not within the standard, replace the

camshaft.

NOTE:

• Measurement should be performed at a temperature of 20°C (68°F).

• Measure outer diameter of each journal at several points, and read the value of most worn location.

Camshaft journal outer diameter:

Standard

25.946 — 25.963 mm (1.0215 — 1.0222 in)

7) Using a dial gauge, check the thrust clearance of the camshaft. If it is not within the standard or if uneven

wear is found, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.

NOTE:

• Measurement should be performed at a temperature of 20°C (68°F).

• Set the dial gauge at end surface of camshaft.

Camshaft thrust clearance:

Standard

0.068 — 0.116 mm (0.0027 — 0.0047 in)

ME-05237

ME-06744

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ME(w/o STI)-213

Cam Carrier

MECHANICAL

8) Check the oil clearance on the camshaft using a plastigauge.

NOTE:

Measurement should be performed at a temperature of 20°C (68°F).

(1) Remove the liquid gasket from cam carrier and front camshaft cap, intake rear camshaft cap and ex-

haust rear camshaft cap.

(2) Clean each camshaft cap and cam carrier journals.

(3) Set the camshaft to the cam carrier.

(4) Place a plastigauge across the camshaft journals of each camshaft and set the camshaft caps.

(5) Tighten the bolts which secure front camshaft cap, intake center camshaft cap, intake rear camshaft

cap, exhaust center camshaft cap and exhaust rear camshaft cap in numerical order as shown in the fig-

ure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

(6) Loosen the bolts (front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust

center camshaft cap and exhaust rear camshaft cap) equally, a little at a time in numerical sequence as

shown in the figure, and remove each camshaft cap.

ME-06745

(5)

(9)

(1)

(2)

(4)

(3)

(11)

(12)

(10)

(7)

(8)

(6)

(4)

(8)

(6)

(5)

(7)

(11)

(10)

(12)

(3)

(1)

(2)

(9)

(13)

ME-06746

(8)

(4)

(9)

(3)

(1)

(2)

(11)

(12)

(10)

(6)

(5)

(7)

(1)

(6)

(8)

(9)

(7)

(12)

(13)

(11)

(2)

(4)

(3)

(5)

(10)

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ME(w/o STI)-214

Cam Carrier

MECHANICAL

(7) Determine camshaft oil clearance by matching the widest point of plastigauge on each journal against

scale printed on a package of plastigauge. If it is not within the standard, replace each camshaft cap and

cam carrier as a set. If necessary replace the camshaft.

Camshaft oil clearance:

Standard

0.037 — 0.072 mm (0.0015 — 0.0028 in)

(8) Completely remove the plastigauge.

ME-06747

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